Stack-wall

ABSTRACT

A masonry wall construction of a plurality of preformed modules employed in lieu of conventionally used concrete block, brick or clay masonry wall structures. Knee braces are provided for properly aligning the first course of modules and subsequent courses are set in a bed of mortar and properly aligned and positioned by the use of brackets and ties and each module is set in place by a crane or other suitable lifting and manipulating device by engagement with eyebolts provided for erection only.

United States Patent 1191 Cook Jan. 29, 1974 [541 STACK-WALL 3,420,0311/1969 Castelli 52/442 Inventor: James J Cook, 200 Penn Square 3,550,8987 H1969 Urslm 52/584 National Bank Building, Oklahoma FOREIGN PATENTS ORAPPLICATIONS City, Okla. 73118 529,964 6/l955 Italy 52/l49 41,806 9/1965Germany. 52/584 [221 2 953,477 12/1949 France 52/749 21 Appl. 196.;212,290

. Primary ExaminerFrank L. Abbott Assistant Examiner-H. E. Raduazo I 521US. Cl. 52/127, 248/226 1), 248/354 s, Anomey, Agent, or Firm clarenceOgden &

52/98, 52/220, 52/503, 52/712, 52/749 Harvey B Jacobson [5!] Int. Cl.E04g 21/18, E04g 21/22 [58] Field of Search 52/l69, 98, 220, 370, 503,[57] ABSTRACT f A masonry wall construction of a plurality of pre- 354226 226 226 249/44 formed modules employed in lieu of conventionallyused concrete block, brick or clay masonry wall structures. Knee bracesare provided for properly aligning [56] References Cited the firstcourse of modules and subsequent courses are UNITED STATES PATENTS setin a bed of mortar and properly aligned and posi- 3,300,920 1/1967Skaare 52/150 tioned by the use of brackets and ties and each mod-3,5l2,325 5/1970 N'iCh OIS 52/584 ule is et in place a crane or othersuitable 532 and manipulating device by engagement with eyebolts 1 erg3,030,061 4/1962 Tennings 248/354 s pmv'ded for mam only 7 Claims, 8Drawing Figures 02:1 I 1 I 1H1 PATENTEDmzQ 1am SHEETZNZ STACK-WALLBACKGROUND OF THE INVENTION 1. Field of the Invention The presentinvention generally relates to a wall construction and more particularlya masonry wall constructed of a plurality of modules of predeterminedstandard sizes such as 8 inch X 4 inch panels together with structurefor erecting a wall in a manner to effect a considerable saving in timeand labor. 2. Description of Prior Art Conventionally, masonry walls areconstructed from bricks, concrete blocks or the like in which theindividual bricks or blocks are laid by hand which results in asubstantial cost for time and labor of the skilled artisan engaged inthis work. Some efforts have been made to reduce the expense involved inconstructuon walls but most efforts have been directed toward theconcept of pouring a complete wall as a monolithic slab either in situin a vertical position or in a horizontal position with the completewall being tilted upwardly to a vertical position after formation. Otherefforts have been made to prefabricate complete building walls at afactory site and then transport them to a building site forinstallation. However, such procedures require rather elaboratemachinery, forms and the like to form a complete wall and eliminateflexibility in design, size and the like of a wall.

SUMMARY OF THE INVENTION An object of the invention is to provide a wallstructure comprising a plurality of standard size modules and anapparatus for setting up the modules into a wall structure which enablesthe modules to be constructed at a point remote from the building siteand effectively transported thereto and then erected to form a buildingwall or the like without requiring the use of elaborate machinery,transportation equipment or erection equipment.

A further object of the invention is to provide a ,wall structureemploying a plurality of modules together with a knee brace for erectingthe initial course of modules and alignment brackets for erectingsubsequent courses of modules with the knee braces and alignmentbrackets being secured by ties disposed in the mortar bed or jointbetween adjacent modules.

Another important object of the present invention is to provide abracket structure for aligning courses of wall modules which engage thevertical surfaces of the modules and include adjustment means to enablelimited adjustable vertical orientation of the upper module to properlyalign it vertically with a lower module.

These together with other objects and advantages which will becomesubsequently apparent reside in the details of construction andoperation as more fully hereinafter described and claimed, referencebeing had to the accompanying drawings forming a part thereof, whereinlike numerals refer to like parts throughout.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of thewall construction illustrating two courses of modules with the kneebrace and brackets being employed.

section line 2-2 of FIG. I illustrating the relationship of the bracketsto the modules.

FIG. 3 is a plan view of the lower module with the brackets beingillustrated in section.

FIG. 4 is a plan view of the lower module illustrating the upper end ofthe knee brace in section.

FIG. 5 is a perspective view of one part of the alignment bracketbetween modules.

FIG. 6 is a perspective view of the other component of the bracket.

FIG. 7 is a perspective view of the knee brace for the module.

FIG. 8 is a fragmental elevational view of a portion of the knee braceillustrating one of the adjustment features thereof.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now specifically tothe drawings, a building wall 10 is disclosed and is constructed from aplurality of substantially identical modules 12 each of which may be 8inches X 4 inches in dimension and is in the form of a panel havingvertically disposed substantially parallel face surfaces which may beprovided with any pattern desired such as simulated brick, stone,concrete block or the like or the panel may have a plain concreteappearance and for the purposes of this application will be defined as asubstantially rectangular rigid panel 14 provided with passageways 16for utility lines and suitable reinforcement (not shown) may be providedin each of the panels to rigidify the same.

The first course of modules 12 are oriented vertically and retained inposition by a knee brace 18. The first course of modules may besupported in any suitable manner such as on a foundation, footing,concrete slab or the like in a well known and approved manner in thebuilding industry with the vertical joint between adjacent modules beingfilled with mortar to provide a sealed joint therebetween. Subsequentcourses of modules 12 are positioned on the lower course in alignmenttherewith with the joints staggered and with a mortar bed between themodules with a bracket assembly 20 being employed between the lowercourse of modules and an upper course of modules.

The knee brace 18 is illustrated in more detail in FIG. 7 and includes alower angle iron member 22 and an upperangle iron member 24interconnected bya turnbuckle assembly 26 to longitudinally adjust themembers 22 and 24 in relation to each other. The lower end of the member22 is provided with a pointed ground stake 28 adjustably attached toeither flange of the member 22 by a plurality of holes 30 providedtherein receiving'a'fastener bolt or pin 32 so that either of theflanges of the member 22 may be disposed vertically with the stake 28being pivotal and oriented vertically when in use as illustrated inFIG. 1. The upper end of the upper member 24 is provided with alongitudinally adjustable angle iron extension 34 having longitudinalslots 36 therein receiving handle-equipped fastener bolts 38 to providea further adjustment of the overall length of the knee brace. The upperend of the extension 34 is pivotally attached to an angle iron member 40having a reinforced slot 42 therein which receives a generallytriangular shaped end 44 of a tie 46 that is embedded in the mortar bedand thus anchored to the wall or a suitable means may be provided foranchoring,

the tie to the lower course of modules 12. A wedge 48 is insertedvertically down through the triangular shaped loop or eye 44 with onesurface of the wedge engaging the bracket 40 above and below the slot 42thereby securing the bracket flat against the lower module 12 so that byadjustment of the turnbuckle 26, the lower module 12 may be accuratelypositioned in vertical orientation.

The bracket assembly 20 includes a rigid one-piece angle iron unit 50bridging the horizontal joint between the lower and upper course ofmodules 12 with one flange of the member 50 having a reinforcedhorizontal slot 52 therein for receiving a triangular eye or loop 54 onone end of a wire tie 56 that includes a similar loop or eye on theother end thereof and is provided with a central offset 58 which isdisposed between the courses of modules and received in the mortar bed.The loop 54 extends through the slot 50 and receives a verticallydisposed wedge 60 tethered to the member 50 by a flexible chain or thelike 62 so that one flange of the angle iron member 50 is secured flushagainst the aligned surfaces of the lower and upper modules.

Each bracket assembly 20 also includes a two-piece component generallydesignated by numeral 64 which includes a lower angle iron member 66having a reinforced horizontal slot 68 adjacent the upper end thereofwhich receives the eye or loop 54 on the end of a wire tie 56 with avertical wedge 70 being received therein and tethered to the angle ironmember 66 by a flexible chain 72 or the like so that angle iron member66 will be fixedly secured to the surface of the lower module with theupper end thereof bridging the joint between the upper and lower panels14 which form the modules 12 as illustrated in FIG. 2. The two-piececomponent 64 of the bracket assembly 20 also includes an upper angleiron member 74 having a downwardly extending leg 76 on one flangethereof and forming a continuation thereof which is pivotally attachedto the outwardly extending flange of the angle iron member 66 adjacentthe upper end thereof by a pivot pin or bolt 78. The flange on the angleiron member 66 to which the leg or extension 76 is pivotally attachedincludes a triangular shaped opening 80 and the inner edge of theextension 76 is provided with a smaller triangular shaped notch 82communicating with the inner edge for receiving a horizontally disposedwedge 84 that is tethered to the angle iron member 74 by flexible chain86 or the like. Thus, by inserting the wedge 84 horizontally asillustrated in FIG. 3, the notch 82 and the extension 76 will engage theinclined apex of the wedge and be forced outwardly as the wedge isinserted thereby clampingly engaging the surface of the upper module byswinging the member 74 inwardly about pivot pin or bolt 78 thus clampingthe module against the one-piece component 50 and orienting the uppermodule in exact alignment with the lower module.

As illustrated, the wire ties may be provided with weakened pointadjacent the outer ends to enable the outer ends thereof to be brokenoff after assembly of the wall. The weakened points may be in the formof notches 88 and the wire ties may be of well known structure whichfacilitate breakage thereof. Also, eyebolts or ties 90 may be providedin the top edge of each module to enable a crane or other liftingequipment to be employed to place the modules in position with theseeyebolts either being removed or broken off after assembly of themodules. Also, each of the wedges are tethered to their associatedstructure to prevent loss thereof and enables assembly of the wall withvery minimum toolsinasmuch as a conventional hammer or other impactinstrument may be employed for securing the knee braces in position andalso the bracket assemblies in position.

The foregoing is considered as illustrative only of the principles ofthe invention. Further, since numerous modifications and changes willreadily occur to those skilled in the art, it is not desired to limitthe invention to the exact construction and operation shown anddescribed, and accordingly all suitable modifications and equivalentsmay be restored to, falling within the scope of the invention.

What is claimed as new is as follows:

1. A wall structure comprising a plurality of courses of modules, eachof said modules being defined by a substantially rectangular panel withthe panels being vertically and horizontally aligned and secured to eachother, and means retaining the modules in position during assembly, saidmeans including a longitudinally adjustable knee brace having means atone end for anchoring to the modules in a lower course and means at theother end for anchoring to the ground, and bracket assemblies securingupper modules in vertical alignment with the lower modules, each of saidbracket assembles comprising a first bracket including a rigid memberextending vertically along one surface of two vertically superimposedmodules in engagement with the surface thereof and bridging the jointtherebetween, a second bracket engaging the opposite surface of themodules, means extending between the brackets for securing them onto themodules, said means being disposed in the juncture between the modulesto vertically orient the bracket assembly in relation thereto, saidsecond bracket including a lower angle iron member rigidly secured tothe means extending between the brackets, and an upper angle iron memberhaving a depending extension pivotally attached to the lower member forpivotal movement about a substantially horizontal axis parallel with theadjacent surface of the modules, and means engaging the extension andthe lower member for swinging the upper end of the extension toward themodules for securing the upper module in place.

2. The structure as defined in claim 1 wherein said knee brace includesa pair of longitudinally aligned and spaced angle iron members, aturnbuckle interconnecting said angle iron members to enablelongituidnal adjustment thereof, said means for engaging the groundsurface including a pointed stake for insertion into the ground, meanspivotally and detachably connecting the upper end portion of the staketo either of the flanges of the angle iron member to enable the kneebrace to be oriented in various positions in relation to the groundsurface, said means on the knee brace engaged with the module includingan angle iron member pivotally connected to the knee brace for pivotalmovement about an axis paralleling the surface of the module to enablethe angle iron member to lay flat against the module, said angle ironmember having a horizontally disposed slot therein, a wire tie securedto the upper edge of the lower module and including a loop projectingthrough the slot, and a wedge extending down through the loop andsecuring the angle iron member to the module.

3. The structure as defined in claim 1 wherein said means for swingingthe upper end portion of the upper knee braces includes a pair oflongitudinally aligned and spaced angle iron members, a turnbuckleinterconnecting said angle iron members to enable longitudinaladjustment thereof, said means for engaging the ground surface includinga pointed stake for insertion into the ground, means pivotally anddetachably connecting the upper end portion of the stake to either ofthe flanges of the angle iron member to enable the knee brace to beoriented in various positions in relation to the ground surface, saidmeans on the knee brace engaged with the module including an angle ironmember pivotally connected to the knee brace for pivotal movement aboutan axis paralleling the surface of the module to enable the angle ironmember to lay flat against the module, said angle iron member having ahorizontally disposed slot therein, a wire tie secured to the upper edgeof the lower module and including a loop projecting through the slot,and a wedge extending down through the loop and securing the angle ironmember to the module.

6. A bracket assembly for retaining vertically superimposed buildingwall modules in vertical alignment and being disposed in bridgingrelation to the joint between vertically aligned and superimposedbuilding wall modules, said bracket assembly comprising a first bracketin the form of an elongated rigid member extending vertically along onesurface of two vertically superimposed modules in bridging relation tothe joint therebetween and in engagement with the surface of bothmodules, a second bracket extending vertically along the oppositesurface of the two modules in substantially opposed relation to thefirst bracket, means extending between the first and second brackets forsecuring them onto the modules, said means being disposed in the jointbetween the two vertically superim posed modules, said second bracketincluding a lower rigid member rigidly secured to the means extendingbetween the brackets, an upper rigid member having a depending extensionpivotally attached to the lower rigid member for pivotal movement abouta horizontal axis generally parallel with the adjacent surface of themodules, and means interconnecting the extension and the lower memberfor swinging the portion of the upper member above the horizontal axistoward the upper module for securing the upper module securely in placeby clamping it between the upper end portion of the first bracket andthe upper end portion of the second bracket.

7. The structure as defined in claim 6 wherein said meansinterconnecting the extension and lower member includes a wedgeinsertable through an opening in the lower member and engaging the inneredge of the extension on the upper member below the axis for forcing theinner edge of the extension outwardly to cause the upper portion of theupper member to pivot about its pivot axis to engage the surface of themodule.

1. A wall structuRe comprising a plurality of courses of modules, eachof said modules being defined by a substantially rectangular panel withthe panels being vertically and horizontally aligned and secured to eachother, and means retaining the modules in position during assembly, saidmeans including a longitudinally adjustable knee brace having means atone end for anchoring to the modules in a lower course and means at theother end for anchoring to the ground, and bracket assemblies securingupper modules in vertical alignment with the lower modules, each of saidbracket assembles comprising a first bracket including a rigid memberextending vertically along one surface of two vertically superimposedmodules in engagement with the surface thereof and bridging the jointtherebetween, a second bracket engaging the opposite surface of themodules, means extending between the brackets for securing them onto themodules, said means being disposed in the juncture between the modulesto vertically orient the bracket assembly in relation thereto, saidsecond bracket including a lower angle iron member rigidly secured tothe means extending between the brackets, and an upper angle iron memberhaving a depending extension pivotally attached to the lower member forpivotal movement about a substantially horizontal axis parallel with theadjacent surface of the modules, and means engaging the extension andthe lower member for swinging the upper end of the extension toward themodules for securing the upper module in place.
 2. The structure asdefined in claim 1 wherein said knee brace includes a pair oflongitudinally aligned and spaced angle iron members, a turnbuckleinterconnecting said angle iron members to enable longituidnaladjustment thereof, said means for engaging the ground surface includinga pointed stake for insertion into the ground, means pivotally anddetachably connecting the upper end portion of the stake to either ofthe flanges of the angle iron member to enable the knee brace to beoriented in various positions in relation to the ground surface, saidmeans on the knee brace engaged with the module including an angle ironmember pivotally connected to the knee brace for pivotal movement aboutan axis paralleling the surface of the module to enable the angle ironmember to lay flat against the module, said angle iron member having ahorizontally disposed slot therein, a wire tie secured to the upper edgeof the lower module and including a loop projecting through the slot,and a wedge extending down through the loop and securing the angle ironmember to the module.
 3. The structure as defined in claim 1 whereinsaid means for swinging the upper end portion of the upper memberincludes a wedge insertable through an opening in the lower member andengaging the inner edge of the extension on the upper member for forcingthe inner edge of the extension outwardly to cause the upper member topivot about its pivot axis to engage with the surface of the module. 4.The structure as defined in claim 3 wherein each module includespassageways to enable installation of utility conduits, and spacersbetween the courses of the modules.
 5. The structure as defined in claim4 wherein said knee braces includes a pair of longitudinally aligned andspaced angle iron members, a turnbuckle interconnecting said angle ironmembers to enable longitudinal adjustment thereof, said means forengaging the ground surface including a pointed stake for insertion intothe ground, means pivotally and detachably connecting the upper endportion of the stake to either of the flanges of the angle iron memberto enable the knee brace to be oriented in various positions in relationto the ground surface, said means on the knee brace engaged with themodule including an angle iron member pivotally connected to the kneebrace for pivotal movement about an axis paralleling the surface of themodule to enable the angle iron member to lay flat against the module,said angle iron member having a horizontally dispoSed slot therein, awire tie secured to the upper edge of the lower module and including aloop projecting through the slot, and a wedge extending down through theloop and securing the angle iron member to the module.
 6. A bracketassembly for retaining vertically superimposed building wall modules invertical alignment and being disposed in bridging relation to the jointbetween vertically aligned and superimposed building wall modules, saidbracket assembly comprising a first bracket in the form of an elongatedrigid member extending vertically along one surface of two verticallysuperimposed modules in bridging relation to the joint therebetween andin engagement with the surface of both modules, a second bracketextending vertically along the opposite surface of the two modules insubstantially opposed relation to the first bracket, means extendingbetween the first and second brackets for securing them onto themodules, said means being disposed in the joint between the twovertically superimposed modules, said second bracket including a lowerrigid member rigidly secured to the means extending between thebrackets, an upper rigid member having a depending extension pivotallyattached to the lower rigid member for pivotal movement about ahorizontal axis generally parallel with the adjacent surface of themodules, and means interconnecting the extension and the lower memberfor swinging the portion of the upper member above the horizontal axistoward the upper module for securing the upper module securely in placeby clamping it between the upper end portion of the first bracket andthe upper end portion of the second bracket.
 7. The structure as definedin claim 6 wherein said means interconnecting the extension and lowermember includes a wedge insertable through an opening in the lowermember and engaging the inner edge of the extension on the upper memberbelow the axis for forcing the inner edge of the extension outwardly tocause the upper portion of the upper member to pivot about its pivotaxis to engage the surface of the module.